Rail bond



July 3, 1928. 1,675,750

F. P. DAHLSTROM ET AL RAIL BOND Filed Sept. 2, 1921 Patented 1.1193, 192s.

FRANK P. DAHLSTBOH AED CHARLES L LABSOIL 0I? WORCESTER, HASSACHUBETTS,

.ASSIGNOIBS` T0 THE AMERICAN STEEL coaroaanoiv 'or Naw JERSEY. I M11- AND WIRE COMPANY `0F NEW JERSEY, A

BOND.

Application illed September 2, 1921. Serial No. 498,128.

This invention relates to rail bonds having rigid terminals fixed to the ends of a flexible' rail bond conductor, and more particularly relates to the shape and composi- .tion of the terminals of rail bonds, wherein the bond terminals are permanently united to the rail bond conductor by -a fusing or welding operation. One obJect of our invention is the provision in a rail bond having a flexible conductor and rigid terminals, of terminals Whch are composed of dissimilar metals, or metals of differing electrical conductivity, and are of novel cross section, whereby the bond terminals are made more readil ladapted for use in applying the rail bon s to the ktrack rails by the well known and increasingly used autogeneous Welding process.

Another object of the invention is to provide a rail bond having terminals of novel construction wherein a cupped face is provided thereon which is adapted to co-operate with an adjacent face ofthe track rail in forming a ocket'having a relatively wide bottom, Whie 1 facilitates the introduction of the welding electrode therein, and lessens the diiiculties met with in supplying the molten metal used in securing the bond terminals to the track rails.

Another objectv of the invention is to provide axrail bond having terminals constructed in such manner that in welding the terminals to the track rails, an edge contact 4is made with the track rails, and a maximum area of rail surface for a terminal of given size is exposed for engagement with the welding metal used in attaching the terminals to the rails, and the conductivity of the rail bond thereby increased.

A further object of our invention is to provide a rail bond of improved construction which permits the composite terminals to be forged to the peculiar shape forming part of this invention and tobe made more dense and homogeneous, in completing the terminals to the desired size and contour.

Further objects of our invention will be made apparent iri the detailed description4 in the following specification, and in theaccompanying drawmgs forming part of this specication, in which:

Figure 1 is an end elevation showing a v rail bond embodying our invention as welded to track rail by means of an electric are.

tors in making rail bonds embodying our invention.

Fi re 4 isl a similar perspective view, showln a modified form of terminal shell adapte for use in Vmaking rail bonds embodying our invention.

Figure 5 is a perspective view, similar to i that of Figure 3 and Figure 4, showing a further modified form of terminal shell,

` usable in making rail bonds embodying our invention. Referring now to the drawings, the numeral 2 designates the' conductor, and 3, in a .general way, the terminals of a rail bond made in accordance with our invention, the railv bond being shown in Figure 1 as secured to a track rail 4 b means of arc welding, the attachment ofY the bond terminal to the rail being secured by the welding metal 5.

By reference to the drawings, it will be seen that one face 6 of I he rail bond terminals 3 is made concave so as to coact with the face of the rail 4 and form a` ocket 7 having a relatively wide bottom, t e lower portion 8 ofthe side of the bond terminal below the concave' face 6 having what is practically aline contact with the track rails, when the terminal is clamped in lace, in readiness for the welding operation y which the terminal is vfastened to the track rail 4.

As experience shows, it is extremel dilicult, particularly in the field, to We d two metals which diier in composition or in electrical conductivity, the terminals 3 of our improved rail bonds areprovided with a ferrous metal shell or crust which is formed of a metal of substantially the same composition or electrical conductivity as the metal of the track rails t0 which the rail bonds are to be applied.

`In building 11p or fabricating the bond terminals, the end of'a bar of steel o r other metal ofk suitable composition is heated and drop forged, so as to form a hollow, thin walledimetal shell 9 of the approximate outi line of the finished bond terminals. This metal shell will be of the cross section shown in Figure 3 or, when desired, lwill be made -as shown in Figure 4 or Figure 5. In all cases, the rail engagin side or face 6 of the 'ferrous metal shell will be curved so as to form a depression or recess 7- therein, having a .wide bottom. ,Y One side of the terminal shells 9 will be open to facilitate the introduction of the metal forming the filling or body portion 10 of the terminals, and another side` thereof will be provided with a boss 11,

I through which the end of the conductor 2 'extends intofthe cavity or interior 12 of the hollow metal shell 9, when the molten metal forming the filling or body portion 10 of the terminal is put into the hollow, trough-like I metal shell, as 'is done in making rail bonds in accordance with our invention.

The molten inetal forming the filling or body portion of the terminals may be supplied in any desired manner, a convenient wayof providing this molten metal is by cuit will be connected to the shell, or preferably to the bond conductor 2, and the other terminal may be a non-metallic electrode, or

in some cases will be the welding pencil itself.

At the commencementof the shell filling operation, an electric arc will be formed soJ as to heat and fuse the inner surfaces of the terminalshell and the end of the conductor which extends into the shell. In this way, the molten metal is supplied and is welded and firmly united to the terminal shell and conductor end, so as to form a substantially integral mass. Y

After the' shell ofthe terminal has been filled with molten metal from the rod ory pencil, the terminal willhave a more or less rough appearance, although vusable in bonding rails. But in order to give the rail bond a neat'fnished appearance, and at the same time to compact and make the metal illi within the terminal shell more. dense, aiil shape the bond terminal to exact sizel and tczontour, tlllief so-formed terminallsare subect o a roug orgin o eration. o 'es having cavities of tlle nry slirgillp and tion of said side below said concave size will be employed. The bond terminals, 00

vafter bein heated to a forging temperature,

are place between the dies and are dro forged therebetween` as has been describe The flash or fin which forms on the termi'- nals in this drop forging operation is then removed,- by shearing or in any other approved inanner, and after -the terminal 3 on each`end of the bond conductor 2 has been forged and finished, a complete rail bond having a neat, finished appearance is produced.

The Iadvantages of my invention will be apparent to those skilled 1n the art. B making rail bonds of the" herein describe sha e and composition, a superior roduct is o tained which, on account of t e composition and sha of its bonding face, enables the rail bon s to be easily and quickl fastenedY to the track rails, by means of t e electric are, in a more secure and effective mannerv than is ordinarily possible with rail bonds as made heretofore.

Various modifications which will suggest metal, said shell extending over all but one side face of said cuprous eore'or body, and said composite terminals ha A a concave the apface on one of the shell covered sides thereof,

with the portion of said side below said oonvcave face adapted to engage the rail when the bond is 2. A rail ut into use.

nd comprising a flexible conductor having T-,head terminals welded to the ends thereof, said terminals having a central core or body fonned of cupros metal and welded to an outer shell of ferrous metal,

. said shell extending over al1 but one side face of said cuprous core or body, and said composite terminals being forged to size andk` shape vand having a concave face `on one of the shell covered sides'the'reof, with the porf ace adapted to engage the rail when the bond is put into use.

In testimony whereof, we have hereunto signed our names. FRANK I?. DAHLSTROM.

' l CHARLES L. LABSQN.

lll 

